Sunshine Garage Mk IV Roadster
The construction of a Factory Five Mk IV Roadster
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Build Overview
Build Blog
Construction steps
Build Checklist
Body buck construction
Front suspension
Front disc brakes
3-link
Rear brakes
Steering rack
Fuel supply
Pedal box
Brake lines
Aluminum
Emergency brake
Footbox fresh air vents
Instrument panel
Glovebox fabrication
Cooling systems
Engine Installation
Hydraulic clutch lines
Photo Album Directory
Fasteners photo album
Body buck album
Front suspension album
Front brakes
3-link
Rear brakes
Steering rack and column
Pedal box
Fuel Tank
Brake lines
Aluminum
e-brake
Footbox vents
Electrical system
Instrument panel
Glove box
Cooling system
Engine installation
Supplemental Technical Data
AN to SAE Conversion
Brake Balance v. Deceleration
Brake System Calculations
Fasteners and fittings
Fluid Line Clamp Spacing
Links to technical information:
Tap and Clearance Drill Sizes
Tools
Road and Track (2013)
Torque specs: Factory Five
Torque specs: SAE Grade 8
Glove box
Fly-arm cutter
Mockup for the glove box
Aluminum flashing from Home Depot
Glove box template made of 4 pieces of 3/4” wood
Template and flashing
Flashing around template
Flashing around template
Retaining ‘ring’: 1/8” plywood
Fiberglassed Al flashing, end piece and retaining ring
Al bent over retaining ring
Door mockup with latch and lock
Cutting the hole for the box in the dash
Holes in the dash
Test fit of glove box
Hinges to be used for glove box door
Box ready for installation
Another view of the box
Test fit of door
Box test fit
Box test fit
Wrapping the interior sides with vinyl covering
The wrap completed
The box with the bottom material in
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